Structural form and method for making architectural structures



April 1970 J. L. FON'IS'AINE 3,506,746

STRUCTURAL FORM AND METHOD FOR MAKING ARCHITECTURAL STRUCTURES 2Sheets-Sheet 1 Filed Dec. 18, 1967 FIG.2

SFIGJ April 1970 J. L. FONTAINE 3,506,746

STRUCTURAL FORM AND METHOD FOR MAKING ARCHITECTURAL STRUCTURES FiledDec. 18, 1967 a Sheets-Sheet 2 United States Patent 3,506,746 STRUCTURALFORM AND METHOD FOR MAKING ARCHITECTURAL STRUCTURES Jean Louis Fontaine,37 Quai de la Tournelle, Paris Seine, France Filed Dec. 18, 1967, Ser.No. 691,358 Claims priority, applicgtitan France, Dec. 20, 1966,

s 8 Int. (:1. E04b 1716; E04g 11/04 US. Cl. 264-32 3 Claims ABSTRACT OFTHE DISCLOSURE The present invention relates to a novel method formanufacturing rapidly and economically architectural structures, whichcomprises the steps of providing supporting elements conveniently fixedin locations corresponding to the projecting points of the roof of thestructure to be constructed, suspending the central portion of a nethaving deformable meshes on said supporting elements while allowing theremainder of said net to hang downwardly so as to constitute the 'basictexture element of the walls, stretching said net from its lower edge,applying upon the stretched net a layer of filling material such asplaster or a convenient plastic material so as to form a shell, andremoving said supporting elements and their fixing means aftersolidification of said shell.

It will be easily understood that when the net is stretched from itslower edge, it will take a general configuration constituted by surfacespresenting regular natural curvatures wherein the tension of the variousstrands of the net shows a trend to become uniform due to thedeformation of the meshes; thus after solidification of the fillingmaterial and removal of the supporting elements the resulting structureconstitutes a large shell submitted to compression stresses with acomparatively uniform fatigue rate which corresponds up to a certainpoint to the tensional fatigue of the various strands of the net.

When the filling material has solidified to a satisfactory degree anydesirable apertures may be cut out in the shell, said aperturescorresponding to any doors, windows, etc., to be provided in the finalstructure.

The supporting elements are preferably constituted by elements having aconvex surface such as portions of spheres, or cylindrical surfaces. Inan advantageous embodiment of the instant method inflatable balloons areused as supporting elements, whereby the transportation, positioning andremoval of said supporting elements are facilitated.

The stretching or tensioning of the net may be effected by attaching aplurality of weights distributed over the length of the lower nets edge.This results in a construction having vertical walls. If on the otherhand the stretching or tensioning of the net is effected by applying toits lower edge obliquely directed forces the resulting structure willcomprise inclined curved walls.

In one embodiment of the present method, which relates, moreparticularly, to comparatively large constructions a layer of cement orconcrete is applied upon the resulting structure after solidification ofthe above mentioned filling material; said cement or concrete layer maybe reinforced by a metallic grid or a similar reinforcement element.

In another embodiment of the instant method a high resistance supportingnet having deformable meshes is suspended on the supporting elements andstretched or tensioned as indicated hereinabove, whereafter anintermediate light-weight web constituted, for instance, by a foil ofplastic material or of another convenient separating material is appliedupon the stretched net; a second net being then placed upon saidintermediate web, whereafter the filling material is applied on saidsecond net. The high resistance supporting net functions as a re-usablemolding or shuttering element. Its lower edge may be provided with aframe to which the tensioning forces may be applied, for instance bymeans of weights suspended on said frame. The intermediate web ofplastic material or the like which separates the two nets prevents thefilling material from penetrating the meshes of the inner or lowersupporting net, thus allowing the latter to be subsequently removed andre-used. Furthermore, the intermediate web facilitates the formation ofa smooth interior shell surface, thus reducing the finishing operationto be subsequently effected on the latter. The intermediate web maycomprise folds or be constituted by a plurality of partially overlappingweb portions so as to adapt the web eonfiguration to the generalconfiguration of the structure to be achieved.

Generally speaking the novel method allows for manu facturingarchitectural structures without resorting to templets and without usingscaffolding structures which are of considerable high cost and theconstruction of which is a time-consuming operation,

The present invention also covers architectural structures produced bythe above-mentioned method.

Further features and advantages of the invention will become apparentfrom the description hereinafter which refers to the appended drawings;the latter show several embodiments of architectural structures producedby the method according to the invention. In the drawings:

FIG. 1 is a schematic perspective view of a structure having arectangular base and a roof with four slopes.

FIGS. 2 and 3 show two other embodiments of a structure, respectively.

FIG. 1 illustrates schematically the way of carrying out the method ofthe present invention with a view to produce an architectural structurehaving a rectangular base and a roof with four slopes.

To this end supporting elements 1, 2, 3, 4, 5 having a convex surfaceare conveniently arranged by means of a convenient scaffolding structureand of convenient attaching elements such as cables; in the exampleshown the supporting elements are advantageously constituted byinflatable balloons. Four of said balloons i.e. balloons 1, 2, 3, 4 aredisposed in respective locations corresponding to the four corners of atheoretical rectangle having the same size as that of the basis of thestructure to be achieved. The fifth balloon 5 is disposed in a locationcorresponding to the gable of the roof. Broadly speaking, the balloonsthus are arranged in respective locations which correspond to theprojecting points of the finished structure.

Mat 6 constituted by a net having deformable meshes (i.e. meshes havingmore than 3 edges, such as square meshes) is disposed upon theabove-mentioned five supporting elements. The central portion of the netwill thus rest upon the five above-mentioned balloons whereas theremainder of the net will naturally hang down in a vertical position onthe sides of the assembly so as to constitute the basic texture elementfor the walls of the structure to be produced.

The net is then stretched or tensioned, for instance by attachingweights such as 9 along its lower edge. The entire net will thenautomatically assume a harmonious configuration constituted by curvedsurfaces wherein the tensional stresses acting on the various strands ofthe net tend to equalize to a certain degree. When the net is thusstretched, or tensioned, a filling material such as plaster or aconvenient plastic material is projected upon the net. When thesolidification of this filling material has reached a satisfactorydegree the supporting elements may be removed and the structure beallowed to rest on the floor while being supported by its lower edge.Any apertures necessary for forming the doors, windows, etc. of thefinal structure may then be cut out.

In a modified embodiment the net instead of being stretched by means ofweights 9 may be tensioned in an oblique direction by means of cables orthe like, one end of which is attached at a plurality of pointsdistributed over the length of the lower net edge, the other end of saidcables being provided with a tensioning weight, and said cable passingover one or several pulleys arranged to determine the direction of thetensional force exerted on the net. In this manner the final structurewill be provided with oblique side walls having a very harmonious curvedconfiguration.

FIG. 2 illustrates another embodiment wherein the supporting elements21-22, 2324, 25-26 are constituted by three pairs of spheres disposed,respectively, at the two ends of straight lines 27, 28, 29 which may bematerialized by rods or bars. The supporting points also comprise twohorizontal bars 32, 33 parallel to the rods 27, 28, 29 and located at alevel higher than that of the latter and above two spaces respectivelylimited, on the one hand by rods 27, 28 and, on the other hand, by rods28 and 29. Two other supporting elements are constituted by two hooks orsimilar elements respectively disposed in two locations 34, 35 comprisedin the vertical median plane perpendicular to the center of the bars ofthe abovementioned rods. When a deformable mesh net 38 is then placedover the above-described supporting points, said net will assumesubstantially a configuration illustrated in the drawing; practicallyall the surfaces defined by the net will be curved in accordance withnatural curvatures.

The filling material is then applied as described hereinabove whereafterthe necessary apertures are cut out in the desired locations.

By varying the number, the nature, the shape, and the locations of thesupporting points of the central net portion, the user may varyinfinitely the configuration of the architectural structure to beachieved.

In the preceding examples it has been shown that the supporting elementsmay be constituted by elements having a convex surface, such as elementsin the form of portions of spheres or cylinders.

Different and more economical supporting elements can also be used; forinstance, at least some of the elements used for a given structure maybe constituted by simple arcs preferably disposed in vertical planes.

Such arcs may advantageously be used in combination with othersupporting elements, preferably disposed on elements higher than therespective apexes of said arcs. The said other supporting elements maycomprise, for instance, portions of spherical surfaces or simple ringswhich are preferably horizontally disposed.

Considering now the example illustrated in FIG. 3, the structure to berealized is a building having a hexagonal base 41 constituted, forinstance, by a regular hexagon.

The uppermost or top supporting element is constituted by a horizontalring 42; three other supporting elements used in combination with saidring are constituted by arcs 44, 45, and 46 the base points of whichcoincide with the corner of hexagon 41; arcs 44, 45, and 46 are placedalong every second side of said hexagon. Each are comprises, forinstance, a lower portion formed by two vertical straight foot portionsthe top ends of which are connected by an appropriately curved line. Thetop ring 42 is in a central location with respect to the base 41, i.e.the centre of said ring is located on the vertical axis 43 which passesor extends through the centre of the hexagonal base 41.

With a view to carrying out the instant method the ring and supportingarcs are arranged in their respective appropriate positions by means ofa convenient scaffolding structure and convenient attaching elementssuch as cables. The above-mentioned supporting elements are thusdisposed in locations which correspond to the projecting points of theroof of the finished structure.

As explained hereinabove with reference to FIGS. 1 and 2 a matconstituted by a net having deformable meshes is disposed upon theabove-described supporting elements in such a way that the centralportion of the net rests on said elements, whereas the remainder of themat hangs freely in a vertical position on all sides of the supportingelements so as to constitute the vertical basic texture for the walls ofthe structure to be produced. The net is then stretched, or tensioned,and a filter material is projected thereupon. Upon solidification of thefiller material the supporting elements may be withdrawn and theresulting structure be allowed to rest with its lower edge upon thefioor, or ground.

The horizontal top ring 42 may be replaced by a convex supportingsurface constituted, for instance, by a portion of a spherical surface.

In the example shown the base of the building to be constructed isconstituted by a regular hexagon; it will be easily understood that thebase could have any other desired shape such as any polygonal shapeother than hexagonal, or a circular or oval shape, or any other desiredconfiguration, even an irregular one.

In a specific case the building, or structure, may have, for instance,an elongated rectangular configuration on the small side edges of whichtwo arcs may be disposed, respectively, so as to produce a buildingpresenting the form of a tunnel.

While several particular embodiments of the invention have been shownand described herein it should be understood that various changes in thepractical execution of the instant method, and in structure andarrangements of the various elements may be made.

What is claimed is:

1. A method of making ground supported architectural structures and thelike comprising the steps of: positioning at least one supportingelement above and spaced from ground level and at the roof of anarchitectural structure to be formed, suspending a deformable meshelement in its central region by placing its central region on saidsupporting elements whereby the lower peripheral portion of saiddeformable mesh element is positioned adjacent ground level and theportion of said deformable mesh element intermediate the central regionand lower peripheral portion is unsupported and hangs freely to providethe basic texture of the side wall of said architectural structure,tensioning said lower peripheral portion downwardly to tension said meshelement, disposing a flexible web over said deformable mesh element,disposing a second deformable mesh element over said web, and applying alayer of solidifiable filling material to said second mesh element toform a structural shell, then, after said layer of solidifiable fillingmaterial has solidified, removing said supporting elements and saidfirst deformable mesh element.

2. A structural form for an architectural structure to be erected andadapted to be covered with a solidifiably formed wall, at least onesupporting element spaced from and above ground level, a deformable meshelement, said deformable mesh element having a central region, a lowerperipheral region and an intermediate region therebetween, said centralregion being suspended upon said supporting element, said lowerperipheral region being disposed adjacent ground level, saidintermediate region being unsupported and freely hanging from saidsuspended central region whereby said intermediate region defines thebasic contour of the said walls of said architectural structure to beerected, means connected to said lower peripheral region for tensioningsaid deformable mesh element downwardly between said supporting elementand ground level, and further comprising a flexible web overlying saiddeformable mesh element and a deformable second mesh element over-lyingsaid flexible web.

3. A structural form for an architectural structure to be erected andadapted to be covered with a solidifiably formed wall, at least onesupporting element spaced from and above ground level, a deformable meshelement, said deformable mesh element having a central region, a lowerperipheral region and an intermediate region therebetween, said centralregion being suspended upon said supporting element, said lowerperipheral region being disposed adjacent ground level, saidintermediate region being unsupported and freely hanging from saidsuspended References Cited UNITED STATES PATENTS 2,616,149 11/1952Waller 26432 2,892,239 6/1959 Nerf 264--32 2,948,047 8/1960 Peeler eta1. 135-1 X 3,355,745 12/1967 Jannuzzi 52-63 X FRANK L. ABBOTT, PrimaryExaminer PRICE C. FAW, 111., Assistant Examiner U.s. c1. X.R.

